Acidizing treatments are typically performed intermittently during the life of a well. However, more recently there has been a desire to perform an increased number of acidizing treatments in order to improve production. The acidizing treatments typically involve highly corrosive acids, such as hydrofluoric (HF), hydrochloric (HCl) and acetic acid, which are known to cause significant corrosion. In the presence of hydrogen sulfide (H2S), these acidizing treatments could cause environmentally assisted fatigue and fracture (i.e. increased fatigue crack growth rates and reduced fracture toughness). A test program is underway to evaluate and quantify the effect of sour acidizing treatments on the fatigue and fracture behavior of welded C-Mn line pipe steels. This paper describes the preliminary findings from fatigue crack growth rate (FCGR) and fracture toughness (FT) tests on as-welded (i.e. unstrained) pipe. All tests were conducted at room temperature (RT) using compact tension (CT) specimens notched in the parent pipe (PP). Frequency scan FCGR tests were performed in the following sour acid conditions: simulated production environment (PE), spent acid without inhibitor and spent acid with residual corrosion inhibitor. The PE consisted of a simulated brine with pH = 4.5 and partial pressure of H2S (pH2S) = 0.21psia. FCGRs in the sour PE were of the order of 20 times faster than in air. The pH2S was the same for the tests in spent acid environments, but the pH was lower (approximately 3.5). As would be expected, the FCGRs were much higher in the low pH environment. The highest FCGRs were observed in the inhibited sour spent acid environment and were up to 100 times faster than in air. Sour FT tests were also conducted in the PE and in spent acid with and without inhibitor. In all cases, the measured FT values were significantly lower than in air. The test in PE exhibited higher FT than in the sour acidizing environment. The lowest FT values were observed in spent acid with inhibitor. Future work will investigate the effect of reeling on the fatigue and FT performance of pipe girth welds in sour acidizing environments.
Acidizing treatments are typically performed intermittently during the life of a well. However, more recently there has been a desire to perform an increased number of acidizing treatments in order to improve production. The acidizing treatments typically involve highly corrosive acids, such as hydrofluoric (HF), hydrochloric (HCl) and acetic acid, which are known to cause significant corrosion, but could also lead to environmentally assisted fatigue and fracture. A study was performed to evaluate the effect of acidizing treatments on the fatigue behavior of welded C-Mn line pipe steels. This paper describes the results of fatigue crack growth rate (FCGR) tests on as-welded (i.e. unstrained) pipe. FCGR tests were conducted at room temperature (RT) in three different acid conditions: fresh acid with corrosion inhibitor, spent acid with corrosion inhibitor and spent acid without corrosion inhibitor. Frequency scan FCGR tests were performed on compact tension (CT) specimens notched in the parent pipe (PP), heat affected zone (HAZ) and weld centerline (WCL). The FCGRs in all three environments were higher than in air and exhibited a frequency dependence. Tests in fresh acid with inhibitor exhibited plateau FCGR values around 20–30 times higher than in air. Tests in spent acid with inhibitor exhibited a strong frequency dependence with plateau FCGR values approximately 80–100 times higher than in air. In spent acid without inhibitor, the plateau FCGR was around 20 times higher than in air, however at the lowest frequencies the FCGR decreased, most likely due to crack closure/blunting effects. This behavior is consistent with the higher corrosion rate in this uninhibited environment. The role of corrosion products in causing crack closure/blunting was further evidenced in tests performed at elevated temperature (165°F / 74°C), where the FCGR at 1Hz was significantly higher than at RT. The plateau FCGR in fresh acid and spent acid with inhibitor was approximately 40–50 times higher than in air, but the FCGR decreased at lower frequency. This is similarly believed to be due to the higher corrosion rates at elevated temperature causing crack closure/blunting. The FCGR in spent acid without inhibitor at 165°F (74°C) was high initially at 1Hz but then decreased sharply, which is consistent with the highest corrosion rates expected at elevated temperature and in the absence of corrosion inhibitor. Paris curve FCGR tests were subsequently conducted at 0.1Hz. Tests were performed in the worst case combinations of microstructure/environment/temperature identified from the frequency scan tests.
Acidizing treatments are typically performed intermittently during the life of a well. However, more recently there has been a desire to perform an increased number of acidizing treatments in order to improve production. The acidizing treatments typically involve highly corrosive acids, such as hydrofluoric (HF), hydrochloric (HCl) and acetic acid, which are known to cause significant corrosion, but could also lead to environmentally assisted fatigue and fracture. A study was performed to evaluate the effect of cyclic plastic strains associated with reeling installation on the subsequent fatigue crack growth rate (FCGR) behavior of welded C-Mn line pipe steel in acidizing environments. The influence of the pH of the acidizing environment on the FCGR performance was also investigated as part of this study. This paper compares the results of FCGR tests on as-welded (i.e. unstrained) pipe with those from strained and aged welds, as well as quantifying the effect of the pH of the acidizing treatments. Strained and aged welds were obtained by subjecting the as-welded pipe to 4 cycles of full-scale reeling simulation, with each cycle corresponding to 1% strain. Small-scale compact tension (CT) specimens were then extracted from the strained welds and aged at 250°C for one hour to simulate strain aging. FCGR tests were performed in spent acid with corrosion inhibitor on specimens notched in the parent pipe (PP), heat affected zone (HAZ) and weld centerline (WCL) in both the as-welded and strained and aged condition. The majority of the tests were conducted at room temperature (RT) along with a select few tests at elevated temperature (165°F / 74°C). Overall, the results of frequency scan tests indicated that reeling did not have a significant effect on the FCGR behavior of welded C-Mn line pipe steel in spent acid with inhibitor, regardless of which microstructure was sampled. Frequency scan FCGR tests were also performed on strained and aged samples extracted from the intrados side of the strained welds and notched in the PP, HAZ and WCL to investigate the influence of pH on FCGR behavior. Tests were performed in spent acid with inhibitor at RT, with the pH ranging from 3.7 to 6. The observed FCGRs were higher than in air and all microstructures exhibited a frequency dependence (i.e. the FCGR increased with decreasing frequency). At pH = 3.7, the maximum FCGR was approximately 30 times higher than in air and at pH = 5 the FCGR increased to approximately 80 times higher than in air. However, a further increase in pH to 6 produced a decrease in FCGR. The increase in the maximum FCGR is believed to be due to the decrease in corrosion rate with increasing pH leading to reduced crack closure/blunting. However, as the pH increased to around 6, the corrosion rate decreased substantially, which is likely due to a substantial decrease in the concentration of hydrogen being generated, resulting in a lower FCGR. Paris curve FCGR tests were subsequently conducted on strained and aged samples at 0.1Hz.
Production risers as well as drilling risers are often exposed to ocean currents. Vortex-induced vibrations (VIVs) have been observed in the field and can cause fatigue failure and excessive drag on the riser. In order to suppress VIV, fairings are often used. This paper presents qualification tests for two types of fairings: the short-crab claw (SCC) fairings and the AIMS dual flow splitter (ADFS) fairings. The short-crab claw fairing design is a novel design patented by the Norwegian deepwater project (NDP). As will be detailed in this paper, both the SCC and ADFS designs offer very low drag, completely suppress VIV, and are effective even when they are in tandem. A model test campaign was undertaken in the 200-m towing tank facility at the ocean, coastal, and river engineering in St. John's, NF, Canada. A rigid pipe with a diameter of 0.3556 m (14 in) was utilized for the experiments. This corresponds to prototype size for a production riser and a 1:3.8 scaled model for a 1.3716 m (54 in) drilling riser. Given that these tests were conducted at prototype scale, they were used to qualify the fairings for field deployment. Both fairings (SCC and ADFS) were very effective in suppressing VIV and reducing drag. The ADFS fairings are most effective for a span to diameter ratio of 1.75. For all fairing geometries, it was found that a small taper increases the fairing effectiveness considerably.
Production risers as well as drilling risers are often subjected to Vortex-induced vibrations (VIV) when exposed to ocean currents. VIV have been observed in the field and can cause fatigue failure and excessive drag on the riser. In order to suppress VIV and reduce drag, fairings are often used. This paper presents hydrodynamic qualification tests for two types of fairings: the short crab claw (SCC) and a tapered dual fin design. The short crab claw fairing design is a novel design that was developed by the Norwegian Deepwater Programme (NDP). As will be detailed in this paper, the SCC design offers very low drag, completely suppresses VIV and reduces riser interference. In 2012, a model test campaign was undertaken to understand and qualify the hydrodynamic performance of fairings at prototype conditions. The program consisted of testing the three fairing geometries and a strake to understand the stand-alone performance in VIV and the performance in interference. This was accomplished by utilizing a single pipe setup for the standalone test and a two-pipe setup for the interference tests. The paper reports the results of the program and draws conclusions on the hydrodynamic performance of the VIV suppression devices tested. Overall, all VIV suppression devices tested were able to suppress VIV with the SCC fairing being the most effective. In all cases tested, the downstream fairings / strakes were very effective in suppressing VIV in an interference scenario where a fairing was placed upstream. Contrary to the well-documented case of two strakes in tandem, in this case the upstream fairings did not reduce the effectiveness of the downstream fairings/strakes.
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